They say good things come in threes. In the case of screening for mining and quarry operations, profit comes in three distinct phases: layered, basic and sharp screening. But how good they are – whether they maximize efficiency and improve the potential for success – depends on having the right screen media on the deck at each phase.
A relatively new method for achieving that goal is a blended screen media approach that incorporates the ideal screen media for each phase and the ideal mix of media for the process overall. The goal of implementing a blended solution is to find the optimal combination of open area and wear life. Hit the sweet spot and you’ll maximize product quality and production by increasing the efficiency of classification while minimizing downtime and maintenance costs.
Optimal Screening
The ultimate goal of every operation is a flawless screening process. The bulk of undersized material passes through the openings in the middle third of the screen deck and the last third of the deck allows all the near-sized particles to find an opening. The final product meets specifications and can be sold for top dollar. However, while a company is often satisfied with achieving optimal screening, it seldom recognizes the potential to increase profits even further.
The key to achieving the most profitable screen surface is finding the right balance between wear life and open area. Increasing open area normally leads to a decrease in wear life while reducing open area usually increases the wear life of the screen media.
Proof of Profit
For a company in Madoc, Ontario, about three hours northeast of Toronto, Canada, implementing a customized blend of screen media positively impacted the operation immediately.
Danford Construction Ltd. has been a family business for more than 50 years. Its Aggregates Division handles a variety of materials in a granite quarry, two limestone quarries, a traprock quarry and eight gravel pits. Danford called in Haver & Boecker Niagara as a consultant to help customize screening for its granite operation. Following a vibration analysis and Haver & Boecker Niagara’s recommendations, Danford customized its deck with the ideal blend of screen media.
“We are getting eight times the wear life out of the new screen set-up, adding two weeks production time per year, and have reduced our screening costs by 75% as a result,” said Jamie Danford, owner of Danford Construction, Ltd.
A Professional Approach
Customized solutions that blend screen media types on the same deck ensure optimum screen media wear life while minimizing downtime and maximizing profit potential. A professional analysis will determine the right combination of open area and wear life appropriate for each of the three phases of screening.
Danford and other mineral processing companies have learned that expert guidance and fully customized configurations can pay for themselves in the short-term and dramatically increase production and profitability over time. From extended screen life and less downtime for change-outs to a greater amount of a higher quality product, producers that deploy a smart blend of screen media can maximize performance in each phase of screening.
Interested in learning more about blended screen media? Contact us today to schedule a consultation at info@haverniagara.ca.
Our global network of experience allows us to solve the most unique problems.
Florian Festge, Haver & Boecker Managing Partner
